Unlock instant, AI-driven research and patent intelligence for your innovation.

Model of warm stone floor material

a technology of warm stone and floor material, applied in the field of engineered flooring, can solve the problems of high installation cost, heavy and difficult installation, weight and expense, etc., and achieve the effects of reducing installation cost and time, reducing overall manufacturing cost, and superior strength

Inactive Publication Date: 2015-01-22
SKALA STONE
View PDF1 Cites 7 Cited by
  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides a cost-effective natural architectural material that is easy to install on walls and floors. The heated floor material is resistant to temperature and humidity changes, making it ideal for a radiant heated floor. The engineering of the tile has created a rigid and stable substrate which is ideal for facing with natural stone. The final product provides significantly superior strength, shock absorption, and damage prevention profiles over existing traditional stone flooring products. The flooring contains tongue and groove style click-to-lock construction, which facilitates easy installation and provides significant installation cost and time savings.

Problems solved by technology

However, natural stone flooring is expensive to install due to both the cost of the stone and the need for highly skilled labor for installation.
Existing stone flooring materials for interior use has a weakness in that most of it is heavy and difficult to install.
However, as thickness increases, so does weight and expense.
Traditionally, stone is difficult to and requires concrete, mortar or mastics when attaching it to floors or walls.
Such methods, particularly when installed on vertical surfaces is not only inconvenient during construction but often lack strength.
The art has attempted to create flooring comprising stone veneers, however such products have been unsuccessful in the market place due to cracking of the stone.
Such materials when available use relatively thick layers of stone negating all or most of the cost savings usually found with veneered products.
The design of Miller suffers in that the tiles are not sufficiently rigid or dimensionally stable which leads to unsightly cracking of the veneer.
Such tiles have never been sold commercially due to these problems.
In a tongue and groove system such as Miller, such tiles are very difficult to replace.
Heated floors are generally a very complex project involving separate installation of the heating system under traditional tile floors.
Such systems typically require multiple days to install.
Such heating systems while they have worked well on conventional tile and stone floors laid atop a bed of mud, have had limited application when applied to composite stone flooring due to cracking or warping of tiles in the presence of heat.
No suitable composite stone flooring material is known that will withstand repeated cycles of heating without damage to the floor.

Method used

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
View more

Image

Smart Image Click on the blue labels to locate them in the text.
Viewing Examples
Smart Image
  • Model of warm stone floor material
  • Model of warm stone floor material
  • Model of warm stone floor material

Examples

Experimental program
Comparison scheme
Effect test

example 1

Composite Architectural Panels

[0029]Referring to FIGS. 1-3, in an embodiment the architectural panel 10 consists of a composite constructed from 4 different materials which are layered. The top layer 1 is a rectangular, veneer of flooring surface of approximately 2.5 mm thickness. The second layer, is a mesh 2 of approximately 0.3 mm in thickness which is attached to the top layer 1 with an adhesive (not shown) to reinforce the top layer 1 and provide protection against shattering. The third layer, a resilient sheet 3, comprises a resilient backer board about 4 mm thick such an Ecoboard or a cement board, which is attached to the second layer 2 with an adhesive (not shown). The fourth layer which comprises a rigid plastic layer 4 with a unique tongue 12 and groove 11 joint structure is attached to the third layer with adhesive.

[0030]In a preferred embodiment the top layer 1 is a natural material such as stone, cork or wood. In a most preferred embodiment the material is marble. In a...

example 2

[0035]Referring to FIGS. 1-4 the stone floor material according to the invention includes all-in-one plate body 10. The plate body 10 is made up of four-layered structure, and the top layer is a marble 1, and the second layer is a metal mesh 2. The metal mesh 2 can be an aluminum mesh, a steel mesh, a stainless steel mesh and so on, and the third layer is a cement plate 3, which is preferably selected from Cellulose Reinforced Cement (“CRC”) and ECOBOARD (ECOBOARD is a multidirectional fiber board made from agricultural byproducts instead of wood and the fourth layer is a base plate 4 of made of plastic selected from plastics such as ABS (acrylonitrile, butadiene styrene), HIPS (high impact polystyrene sheet), PP (polypropylene) or other suitable polymers known in the art.

[0036]The composite plate body is formed by bonding the four layers with a. suitable bonding agent. Along two adjacent edges, the plastic layer 4 has a plurality of rectangular tongues 12, that protrudes beyond the...

example 3

Heated Composite Flooring

[0038]The architectural panels of Example 1 can readily be heated by incorporating a heating element within the composite layers.

[0039]Referring to FIGS. 7a and 7b and 7c and 7d, heated floor tiles can be constructed by creating a groove 15 in the bottom of resilient layer 3 and placing a resistance heating element 16 into the groove 15 prior to bonding plastic base 4. A connector 17 is provided for attaching adjacent tiles together and to a source of electricity. The connectors may be male and female connectors or any connector design which allows adequate electrical contact. Optionally, any gaps where the connector exits the floor tile can be filed with a plug 32. The heat output from the floor can be controlled with a thermostatic controller which either senses room or floor temperature.

[0040]The groove 15 can take any pattern, but a serpentine pattern which starts and ends close from edge to edge is preferred to provide adequate heat. In areas where more...

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
Login to View More

PUM

PropertyMeasurementUnit
thicknessaaaaaaaaaa
thicknessaaaaaaaaaa
thickaaaaaaaaaa
Login to View More

Abstract

The present invention comprises an engineered architectural material suitable for flooring or cladding walls which is capable of withstanding heat and humidity and methods of manufacturing thereof The architectural material of the present invention is particularly suited for use with natural stone veneers and when constructed in accordance with the present invention such flooring is resistant to cracking and delamination. An embodiment of the invention further comprises an integrated electric resistance heater embedded in the material.

Description

[0001]This application claims priority to and is a continuation-in-part of PCT application PCT / KR2012 / 003151 filed on Apr. 24, 2012 which is a PCT application of Chinese patent application CN2011204369163 filed on Apr. 11, 2011.FIELD OF THE INVENTION[0002]This invention is about an engineered flooring which is capable of withstanding heat and humidity and methods of manufacturing thereof Flooring of the present invention is particularly suited for use with natural stone veneers and when constructed in accordance with the present invention such flooring is resistant to cracking and delamination. One embodiment of the invention integrates a radiant heat source to provide heated floors.BACKGROUND OF THE INVENTION[0003]Natural stone flooring is a product for which there is high demand because of its beauty and resistance to wear. However, natural stone flooring is expensive to install due to both the cost of the stone and the need for highly skilled labor for installation.[0004]Existing...

Claims

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
Login to View More

Application Information

Patent Timeline
no application Login to View More
Patent Type & Authority Applications(United States)
IPC IPC(8): B32B3/06E04F15/04E04F15/02E04F15/08B32B5/02B32B9/00B32B38/10B32B3/30B32B21/04B32B38/00E04B5/48
CPCE04B5/48B32B2419/04E04F15/041E04F15/082B32B5/028B32B9/002B32B21/04B32B3/06B32B3/30B32B38/0004B32B38/10B32B2250/04B32B2250/05B32B2305/08B32B2305/38E04F15/02038E04C2/525E04F2201/0115Y10T442/10Y10T428/24612Y10T428/24777Y10T156/1062
Inventor SON, YU-SUNG
Owner SKALA STONE